Heat exchanger with bypass seal

ABSTRACT

A heat exchanger includes a core with a plurality of passages arranged therein each having an opening positioned adjacent an end portion of the core. A manifold is positioned adjacent the core end portion and includes an inlet and an outlet opening. The manifold includes a divider wall that extends internally therein and that forms separated inlet and outlet passages that are in communication with the respective inlet and outlet openings. The heat exchanger includes a metallic seal interposed between the divider wall and the core to provide a seal therebetween. The seal is constructed to impose a biasing force between the divider wall and the core to provide the desired seal, thereby minimizing or eliminating any unwanted bypass of fluid or gas within the manifold during heat exchanger operation and increasing heat exchanger operating efficiency.

FIELD OF INVENTION

This invention relates generally to the field of heat exchangers and, more particularly, to heat exchangers that are specifically configured to include a bypass seal disposed internally therein to maintain the separation of heat exchanger inlet and outlet flow within the heat exchanger, thereby improving heat exchanger operation efficiency.

BACKGROUND OF THE INVENTION

The present invention relates to heat exchangers that are generally configured having one or more manifold members that are constructed to receive and/or dispense a particular fluid or gas in need of cooling, and a core member that is connected to the manifold members to receive the fluid or gas in need of cooling by conductive and convective heat transfer. The heat exchanger can also include one or more manifold members constructed to receive and/or dispense a particular cooling fluid or gas, that are placed into contact with the core member. Such heat exchangers known in the art can be configured having a single or multiple pass hot-side or cold-side designs.

The core member is typically configured to provide a desired degree of heat transfer. Generally, the core comprises a plurality of hollow heat transfer passages that are provided in number sized and position to permit a desired degree of fluid or gas flow therethrough. These heat transfer passages may also be configured having extended inside or outside surfaces that are specially designed to promote desired heat transfer.

Referring to FIG. 1, a particular type of heat exchanger 10 known in the art is a shell and tube heat exchanger that comprises a shell 12 or body that surrounds the core 14. For purposes of clarity and reference, the core is illustrated with only two passages instead of being fully loaded with a plurality of passages. In a two-pass heat exchanger design, the manifold 16 is attached to one end 18 of the shell and includes both an inlet opening 20 and an outlet opening 22. This type of heat exchanger is used in applications such as for cooling exhaust gas from an internal combustion engine using an exhaust gas recirculation system.

In this example, the core includes a first end 24 that is positioned adjacent the manifold and a second end 26 that is positioned adjacent a closed end 28 of the shell 12. The manifold 16 includes a divider wall 30 that operates to form separate inlet and outlet passages 32 and 34 therein. Hot exhaust gas entering the manifold inlet passes into openings in the first end 24 of the core that are in communication with the manifold inlet passage 32, exits the second end 26 of the core, is directed into passage openings in the core second end that are in communication with the manifold outlet passage 34, and is passed for a second time through the core. As this occurs, the gas traveling through the core is cooled by contact that is made between a cooling medium circulated within the shell and the core. The exhaust gas then exits the core first end 24 through passage openings that are in communication with the manifold outlet passage, and is routed out of the heat exchanger via the exhaust outlet opening 22.

A problem known to exist in heat exchangers configured in the manner described above involves the existence of undesired gas flow bypass within the heat exchanger between the gas inlet and gas outlet streams; specifically, gas bypass that occurs within the manifold gas inlet and gas outlet passages by virtue of a gap that exists between the manifold divider wall and the core. Past attempts at addressing this situation have involved the use of an elastomeric seal between the divider wall and the core. However, the use of such elastomeric seals have not proven effective due to the high operating temperatures that exist within the manifold, which can exceed 315° C. metal temperature. Such internal exhaust gas bypass is undesired as it can adversely impact heat exchanger operating efficiency. If the divider wall is structurally attached to the core, for example by welding or brazing, destructive thermal stresses may arise, reducing heat exchanger life

It is, therefore, desired that a heat exchanger be constructed in a manner that reduces or eliminates unwanted internal bypass of inlet and outlet gas therein. Is desired that such heat exchanger be constructed in a manner that permits the use of existing heat exchanger parts or elements with minimal if any modification. It is further desired that such heat exchanger be constructed in a manner that neither adversely impacts other heat exchanger performance properties, nor adversely impacts construction by using materials and methods that are readily available to facilitate cost effective manufacturing and assembly of the same.

SUMMARY OF THE INVENTION

Heat exchangers constructed in accordance with this invention comprise a core having a plurality of passages arranged therein that can be configured to provide multi-pass flow of gas or fluid therein. The plurality of passages each have openings positioned adjacent an end portion of the core.

A manifold is positioned adjacent the core end portion and includes a gas or fluid inlet and a gas or fluid outlet. The manifold further includes a divider wall that extends internally therein forming a gas or fluid inlet passage that is in communication with the gas or fluid inlet, and forming a gas or fluid outlet passage that is in communication with the gas or fluid outlet and that is separate from the inlet passage.

The heat exchanger further includes a metallic seal interposed between the divider wall and the core end portion to provide a seal therebetween. The metallic seal is configured to create a biasing force between the divider wall and core when the manifold and core are assembled together. The biasing force operates to provide the desired seal between the manifold and core to minimize or prevent the unwanted bypass of fluid or gas within the manifold during heat exchanger operation, thereby increasing heat exchanger operating efficiency.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more clearly understood with reference to the following drawings wherein:

FIG. 1 is a cross-sectional view of a prior art heat exchanger;

FIG. 2 is a top view of a manifold portion of the heat exchanger from FIG. 1;

FIG. 3 is a cross-sectional view of a manifold portion of a heat exchanger of this invention comprising a bypass seal according to a first invention embodiment;

FIG. 4 is a cross-sectional view of a manifold portion of a heat exchanger of this invention comprising a bypass seal according to a second invention embodiment;

FIG. 5 is a cross-sectional view of a manifold portion of a heat exchanger of this invention comprising a bypass seal according to a third invention embodiment; and

FIG. 6 is a cross-sectional view of a manifold portion of a heat exchanger of this invention comprising a bypass seal according to a fourth invention embodiment.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to heat exchangers used for reducing the temperature of an entering gas or fluid stream. The particular application for the heat exchangers of the present invention is with vehicles and, more particularly, to cool an exhaust gas stream in an exhaust gas recirculation (EGR) system, or to cool a pressurized air intake stream in a turbocharged or supercharged engine system. However, it will be understood that this is only an exemplary embodiment. It will be readily understood by those skilled in the relevant technical field that the heat exchanger configurations of the present invention described herein can be used in a variety of applications.

Generally, the invention involves use with heat exchangers that are similar to that described above and as illustrated in FIG. 1 having a shell and tube design.

As mentioned above, the core includes a plurality of passages or tubes disposed therein and can be referred to as a tube bundle. The core comprises a plurality of passage openings positioned adjacent the shell open end 18 when the core is disposed within the shell. The core passages positioned in communication with the manifold inlet passage facilitate a first pass of exhaust gas through the core, and the core passages positioned in communication with the manifold outlet passage facilitate a second pass of exhaust gas through the core.

The shell includes a cooling inlet port (not shown) and a cooling outlet port 36 for circulating a desired cooling medium within the shell that contacts the core and the plurality of passages to reduce the temperature of the gas as it is passed therethrough. Depending on the particular application, the cooling inlet and outlet ports can be provided in the form of manifolds that are attached to the shell.

Referring to FIG. 2, the manifold 16 is attached to the shell 12 and includes inlet and outlet openings 20 and 22. The inlet opening 20 is positioned and configured to receive gas or fluid and direct the gas or fluid into the heat exchanger and, more specifically, to the portion of the core passages in communication with the manifold inlet passage 32. The outlet opening 22 is positioned and configured to receive gas or fluid exiting the portion of the core passages in communication with the manifold outlet passage 34.

As illustrated, the manifold inlet opening 20 is disposed through a top surface 38 of the manifold and is positioned within a first portion of the manifold top surface. It is understood that the opening may be on the side or other location of surface 38. In such preferred embodiment, the manifold outlet opening 22 is also disposed through the top surface 38 and is positioned along a second portion of the manifold top surface. Additionally, as shown in FIG. 2, diffuser vanes 40 can be positioned within the manifold downstream from the inlet opening 22 for the purpose providing a desired gas or fluid entry flow path within the heat exchanger.

FIGS. 3 to 5 each illustrate sectional views of the manifold as used with heat exchangers of this invention. The manifold 42 includes a divider wall 44 therein that projects outwardly away from an inside portion of the top surface 38. The divider wall 44 operates to form a distinct and separate inlet passage 46 and outlet passage 48 within the manifold that each communicate with respective manifold inlet and outlet openings 50 and 52. The divider wall extends lengthwise internally within the manifold separating the inlet and outlet ports, and forming a partition along the core passages that are in communication with the manifold inlet passage and outlet passage.

As illustrated in these figures, the manifold is configured internally to accommodate attachment with an end of the shell and adjacent a first end of the core. As shown each of FIGS. 3 to 5, the end of the core is actually disposed a partial distance into the manifold when the manifold is connected to the shell, as illustrated in schematic by the line 54. It may also be located on the end of the shell in the case of a flat plate configuration of the core endplate.

As discussed above, an issue that exists with respect to prior art heat exchangers is the unwanted bypassing of gas or fluid within the manifold. This is caused by a gap or space that may exist or develop between an end portion of the divider wall and an adjacent surface of the core. While attempts have been tried to address this issue through the use of an elastomeric seal, the use of such elastomeric seal has not prevented such leakage. This is due to the undesired distortion, softening, or disintegration of the seal at the heat exchanger operating metal temperatures of 315° C. or greater.

FIG. 3 illustrates a first embodiment of the invention as used with heat exchangers to remedy this problem. In this first embodiment, the manifold 42 includes a seal 56 that is interposed between the divider wall 44 and an adjacent core surface 58, and that may be attached to at least one of the divider wall or core. In a preferred embodiment, the seal 56 is formed from a metallic material and is configured having a first segment 60 that is attached to an adjacent surface of the divider wall 62, and having a second segment 64 that is integral with the first segment and that projects inwardly towards the outlet passage 48.

The second segment 64 includes an end 66 that is configured to abut against the adjacent core surface 58 when the manifold and core are assembled together. The combined configuration of the first and second segments provide a seal profile resembling a “V” or having a “V-shaped” profile. The seal 56 is configured having a length that spans the distance between the divider wall and core within the manifold to provide a leak-tight seal against the core for the length of the core.

The seal can be formed from any type of metallic material that is capable of functioning to provide a desired seal when placed into contact with or pressed against the core, and that is capable of retaining a desired sealing engagement against the core when exposed to heat exchanger operating metal temperatures, which may exceed 315° C. Additionally, the seal can be formed by machining, stamping, rolling or other process, depending on the particular material selected, configuration, and available manufacturing equipment. In an example embodiment, the metallic seal is formed from stainless steel and is made by a stamping process.

In a preferred embodiment, the angle of projection as measured between the seal first and second segments is in the range of from about 110 to 170 degrees. Functionally, it is desired that the angle provide a sufficient bias and loading force onto the core when installed to provide a tight seal therebetween during the high-temperature operating conditions within the heat exchanger. Additionally, it is desired that first and second segments each be of sufficient dimension to help provide the above-noted desired loading force onto the core.

The seal can be attached to the divider wall by conventional methods, such as by welded, bolted, riveted attachment or the like. In an example embodiment, the seal 56 is attached by welding. Additionally, while the seal is shown in FIG. 3 as being attached to the inlet passage side of the divider wall 44, the seal can alternatively be attached to the outlet passage side of the divider wall if so desired.

FIG. 4 illustrates a second embodiment of the invention as used with heat exchangers. In this second embodiment, like the first embodiment, the manifold 42 includes a seal 68 that is interposed between the divider wall 44 and the core. In this particular embodiment, the seal 68 is formed from the same types of metallic materials disclosed above for the first embodiment, and is generally configured having an “M-shaped” profile.

Specifically, the seal 68 is configured having a central groove 70 that is sized and shaped to accept placement of the divider wall end 72 therein, and having a pair of raised ridges 74 surrounding the groove 70 that operate to help center placement of the divider wall end within the seal. Moving away from each raised ridge, the seal 68 includes a pair of base members or feet 76 that are configured for placement against the core. Configured in this manner, the seal groove 70 forms a seal with the divider wall and the seal feet 76 form a seal with the core.

Additionally, the seal 68 is provided in the form of a one-piece construction comprising the groove, raised ridges and feet that together operate to provide a self-loading mechanism between the divider wall and core, when the core and manifold are assembled together. This operates to provide and maintain a desired loading force for forming a seal between the divider wall and the core during heat exchanger operation. In a preferred embodiment, the seal 68 is formed from stainless steel and is made by a stamping process.

Although the seal 68 as illustrated in FIG. 4 is shown without being attached to the divider wall other than by loading force, if desired, the seal 68 can be attached to the divider wall. For example, the seal can be attached by welded attachment or the like at the interface between the divider wall and the groove.

FIG. 5 illustrates a third embodiment of the invention as used with heat exchangers. In this third embodiment, like the first embodiment, the manifold 42 includes a seal 78 that is interposed between the divider wall 44 and the core 54. In this particular embodiment, the seal 78 is formed from the same types of metallic materials disclosed above for the first embodiment, and is generally configured having a “C-shaped” profile.

Specifically, the seal 78 is configured having a central groove 80 that is sized and shaped to accommodate placement of the divider wall end 82 therein. The seal 78 includes a pair of legs or ends 84 that are integral with the groove and that each extend along respective opposed wall surfaces of the divider wall. The legs are attached to the divider wall by the same attachment methods noted above for the first invention embodiment. The seal 78 includes a base 86, defining an outside surface of the groove from which the legs extend, and that is positioned against an adjacent core surface 88. Configured in this manner, the seal legs 84 form a desired seal with the divider wall, and the seal base 80 forms a desired seal with the core.

Additionally, the seal 78 is provided in the form of a one-piece construction comprising the groove, legs, and base. The legs project outwardly from the base at less than a 90-degree angle, thereby providing a loading mechanism when the legs are each secured to the divider wall and the core and manifold are assembled together. This loading mechanism imposes a desired biasing force against the core surface to provide the desired seal between the core and seal during heat exchanger operation. In a preferred embodiment, the seal 78 is formed from stainless steel and is made by a stamping process.

FIG. 6 illustrates an alternative embodiment of the invention whereby the sealing mechanism between the divider wall 44 and the core 54 is provided without the use of an external element. Rather, in this specific embodiment, the sealing mechanism is provided by the manifold divider wall having an end 90 that is specially configured to complement and fit together with a complementary surface portion 92 of the core. In an example embedment, the manifold divider wall is configured with an end 90 that is sized and shaped to fit within a groove 92 disposed within the adjacent core surface to provide a tongue and groove attachment mechanism therebetween.

While specific invention embodiments useful with heat exchangers have been described and illustrated, it is to be understood that these embodiments are only exemplary of the many different types of inventive seals that can be installed and used with heat exchangers for the purpose of minimizing or eliminating bypass flow within the heat exchanger hot-side manifold within the scope of this invention.

Additionally, although the different embodiments of this invention have been described and illustrated as being positioned within a hot-side manifold having a particular inlet or outlet configuration, it is to be understood that heat exchanger seals of this invention can be used in other types of heat exchanger manifolds configured other than that specifically described and/or illustrated that generally use the interaction of a divider wall with the core to separate hot-side inlet and outlet gas or fluid flow therein.

Further, although the specific embodiments of this invention had been described in the context of a shell and tube-type heat exchanger, it is to be understood that the seal embodiments of this invention can be used with other types of heat exchangers, such as bar and plate heat exchangers, that use divider walls within a heat exchanger hot-side manifold to provide a seal between and separate inlet and outlet flow streams.

Heat exchangers comprising seals constructed in accordance with this invention operate to minimize or eliminate the unwanted bypass of gas or fluid within the heat exchanger manifold to enable the realization of improved heat exchanger operational efficiency. 

1. A heat exchanger comprising; a core comprising a plurality of passages arranged therein for providing multi-pass flow of gas or fluid therein, the plurality of passages each having openings positioned adjacent an end portion of the core; a manifold adjacent the core and including a gas or fluid inlet and a gas or fluid outlet, the manifold including a divider wall extending therein forming a gas or fluid inlet passage in communication with the gas or fluid inlet that is separated from a gas or fluid outlet passage in communication with the gas or fluid outlet; and a metallic seal interposed between the divider wall and the core.
 2. The heat exchanger as recited in claim 1 wherein the seal is configured having a first portion in contact with the divider wall, and a second portion in contact with the core, the first and second portions being integral with one another.
 3. The heat exchanger as recited in claim 2 wherein the first portion is in contact with the divider wall, and the second portion is biased against the core.
 4. The heat exchanger as recited in claim 3 wherein the second portion departs from the first portion at an angle of departure of less than about 180 degrees.
 5. The heat exchanger as recited in claim 2 wherein the first portion is a groove and an end of the divider wall is disposed therein.
 6. The heat exchanger as recited in claim 5 wherein the seal includes ridges on each side of the groove, and further includes a base that contacts the core and that is common to each of the ridges.
 7. The heat exchanger as recited in claim 6 wherein the seal comprises a one-piece construction.
 8. The heat exchanger as recited in claim 5 wherein the seal includes a pair of legs extending from the groove that contact respective opposite surfaces of the divider wall, and wherein the groove outside surface defines a base portion that contacts the core.
 9. The heat exchanger as recited claim 8 wherein the legs are each attached to the respective surfaces of the divider wall.
 10. The heat exchanger as recited in claim 8 wherein the seal comprises a one-piece construction.
 11. A heat exchanger comprising: a shell having an internal chamber defined by an open end and a closed end; a core disposed within the shell and comprising a plurality of passages arranged therein, the passages including openings positioned adjacent an end of the core; a manifold connected to the shell open end and positioned adjacent the end of the core, the manifold including an inlet and an outlet, the manifold including a divider wall defining separate inlet and outlet passages in communication with a respective inlet and outlet; and a metallic seal interposed between the divider wall and the core, the seal having a one-piece construction and providing a biasing force therebetween.
 12. The heat exchanger as recited in claim 11 wherein the seal includes a first portion that is attached to the divider wall, and a second portion that is pressed against a surface of the core, the first and second portions being integral with one another.
 13. The heat exchanger as recited in claim 12 wherein the seal first portion and second portion are have an angle of departure from one another of less than about 180 degrees.
 14. The heat exchanger as recited in claim 11 wherein the seal includes a groove and the divider wall includes an end that contacts the groove.
 15. (canceled)
 16. The heat exchanger as recited in claim 14 further comprising a pair of legs extending from the groove and contacting opposite surfaces of the divider wall, the groove having an outside surface defining a base for contacting a core surface, wherein the seal has a “C-shaped” configuration.
 17. An exhaust gas cooler comprising: a shell having an internal chamber and having a coolant inlet and a coolant outlet for facilitating the passage of a coolant within the chamber; a core disposed within the shell and comprising a plurality of passages for accommodating the passage of exhaust gas therethrough, the passages having an outside surface that is in contact with the coolant within the shell; a manifold connected to the shell and positioned adjacent the core, the manifold including a divider wall that projects towards the core and that defines inlet and outlet passages within the manifold that are in communication with respective portions of the core; and sealing means interposed between the divider wall and the core to provide a seal therebetween, the sealing means being formed from a metallic material.
 18. The cooler as recited in claim 17 wherein the sealing means is separate from the divider wall and provides a biasing force against the core to provide a sealing force thereagainst.
 19. The cooler as recited in claim 18 wherein the sealing means includes a first member that provides a seal against an end of the divider wall, and a second member that provides a seal against a section of the core adjacent the divider wall, the first and second members being integral with one another.
 20. (canceled)
 21. A heat exchanger comprising: a core comprising a plurality of passages arranged therein for providing multi-pass flow of gas or fluid therein, the plurality of passages each having openings positioned adjacent an end portion of the core; a manifold adjacent the core and including a gas or fluid inlet and a gas or fluid outlet, the manifold including a divider wall extending therein forming a gas or fluid inlet passage in communication with the gas or fluid inlet that is separated from a gas or fluid outlet passage in communication with the gas or fluid outlet; and a non-elastomeric seal interposed between the divider wall and the core. 